Hyundai R140-7 Service Manual Download

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Service Guide

Crawler Excavator

Summary of Contents for R140-7

Page 1: ...Service Guide Crawler Excavator...

Page 2: ...ain Components 19 4 1 Main Control Valve 4 2 Main Pump 4 3 Pilot Circuit 4 4 Swing Motor 4 5 Travel Motor 4 6 Remote Control Valve 4 7 Remote Control Pedal 4 8 Turning Joint 4 9 Safety Valve 4 10 Othe...

Page 3: ...Display on Cluster 1 13 Malfunction of Cluster or Mode Selection System 1 14 Accel Actulator 1 15 Engine Speed Sensor not for excavators with QS engines 1 16 Engine rpm control System 1 17 Hydraulic O...

Page 4: ...Page3 Construction Equipment Specification Comparisions...

Page 5: ...4250 Isuzu CC 4BG1TC 4329 Hydraulic pump LPM 2 130 1 226 Oper Pressure Attachment Power boost Travel Swing Kg cm2 330 360 330 240 325 325 275 305 350 350 Swing speed Travel speed rpm Km h 13 6 3 3 5 5...

Page 6: ...DT 4990 Isuzu A 4BG1TC 4329 Hydraulic pump LPM 2 168 276 Oper Pressure Attachment Power boost Travel Swing Kg cm2 330 360 330 240 325 355 355 325 350 350 350 Swing speed Travel speed rpm Km h 12 1 3 7...

Page 7: ...125 6494 47 1600 Hydraulic pump LPM 2 220 2 206 2 180 2 185 Oper Pressure Attachment Power boost Travel Swing Kg cm2 330 360 330 240 325 355 355 280 350 350 235 350 370 350 Swing speed Travel speed r...

Page 8: ...Page7 Construction Equipment Hydraulic System...

Page 9: ...torage Hyd Pump Create oil flow to transmit the power Control Valve Direction control of actuator Actuator Working device such as cylinder motor and etc Cylinder Inline movement Motor Rotating movemen...

Page 10: ...er of oil passage to reduce oil flow Pipe or hose Main line Pilot line Drain or internal leakage Color code Supply line red Return line blue Suction line green Pilot line brown Drain or internal leaka...

Page 11: ...valve Direction controlling device to prevent reverse flow One check valve pilot line in one block Cooler Exhaust the heat of hyd oil Shut off valve Hyd tank Hyd oil storage Filter Filtering all the...

Page 12: ...pump Discharge amount of pump are flexible dependng on the pressure at actuator such as cylinder and motor Pressure control valve Relief valve Regulating valve Safety device to protect hyd component s...

Page 13: ...e 2 way 3 way For double acting For single acting Double acting Reducing vave It is used for low pressure circuit When the supplied pressure reach to required value supplied oil is cut off Controlling...

Page 14: ...ntrol by spring tension Control valve is fixed with selected direction N neutral position Motor Rotating device Reversible motor Irreversible motor rotate one direction only Pressure switch Button con...

Page 15: ...clutch Applied by spring force Released by hydraulic pressure Shuttle valve Two check valve in one block Oil flow achieved by pressure difference between left light hand side Heater Logic valve Is co...

Page 16: ...Page15 Construction Equipment 3 Hydraulic Circuit 3 1 Main Circuit...

Page 17: ...Page16 Construction Equipment 3 2 Pilot Circuit Crawler Type...

Page 18: ...Page17 Construction Equipment 3 3 Pilot Circuit Wheel Type...

Page 19: ...ge18 Construction Equipment 3 4 Oil Return Circuit Return Pressure Bar Model Oil Cooler By pass 5 R360LC 7 3 5 R290LC 7A 1 5 3 R210LC 7 3 5 5 3 3 R450LC 7 3 R320LC 7 R200W 7 3 R180LC 7 1 5 R140LC 7 1...

Page 20: ...Page19 Construction Equipment R210LC 7 4 1A Main Control Valve Kawasaki 4 Main Components...

Page 21: ...Page20 Construction Equipment R210LC 7 Upper view Side view...

Page 22: ...Page21 Construction Equipment Bottom view Side view R210LC 7...

Page 23: ...Page22 Construction Equipment R210LC 7 LH RH...

Page 24: ...Page23 Construction Equipment R210LC 7 R290LC 7A 1 Foot Relief Valve...

Page 25: ...Page24 Construction Equipment R210LC 7 R290LC 7A 2 Direction Control Valve...

Page 26: ...tion Equipment R210LC 7 R290LC 7A Neutral Position Operation Position Center Bypass valve Load check valve Port Relief valve Port Relief valve Port Relief valve Port Relief valve Load check valve 3 Po...

Page 27: ...Page26 Construction Equipment R210LC 7 R290LC 7A...

Page 28: ...e27 Construction Equipment R210LC 7 R290LC 7A Make Up valve Port Relief valve Main Relief valve Main Pump Load check V V Main Relief valve Port Relief valve Main Pump 4 Main Relief Valve Load Check Va...

Page 29: ...Page28 Construction Equipment R210LC 7 R290LC 7A...

Page 30: ...Page29 Construction Equipment 5 Arm In Operation Regeneration Improve arm in speed Prevent arm cylinder cavitation...

Page 31: ...Page30 Construction Equipment...

Page 32: ...Page31 Construction Equipment Arm Roll Out...

Page 33: ...Page32 Construction Equipment 6 Boom Priority System Boom Swing Operation...

Page 34: ...Page33 Construction Equipment 7 Straight Travel Valve...

Page 35: ...Page34 Construction Equipment R290LC 7A 8 Boom Arm Holding Valve Boom Holding valve closed Boom Holding valve open Pal Boom spool Pal Pal...

Page 36: ...Page35 Construction Equipment R290LC 7A 9 Auto Idling Control System Neutral Position Operated Position...

Page 37: ...Page36 Construction Equipment R290LC 7 10 Straight Travel Valve at Neutral position...

Page 38: ...Page37 Construction Equipment R290LC 7 11 Travel and Swing Simultaneously...

Page 39: ...ATIVE RELIEF VALVE 1 SEC RELIEF V V BUCK SEC RELIEF V V BM FRONT VIEW DRAIN SWING PORT Drain2 Sw Prior Boom2 P1 OUTER PUMP TRAV RIGHT Straight Trav V V SWING SWING PRIORITY ARM1 DOZER OPTION C BOOM1 B...

Page 40: ...ment DRAIN SWING PORT OPTION PORT ARM2 BOOM 1 OPTION 1 side BUCKET TRAVEL LEFT EXTRA A OPTION ARM REGENERATION Lb1 Lb2 Lb1 Lb2 L01 L01 K1 K4 K3 Zm PLUG PLUG Zm K3 K4 Qr Regeneration Power boost Orific...

Page 41: ...ARM1 DOZER OPTION SWING Qr REGENERATION ARM1 OPTION EXTRA C SWING STRAIGHT TRAVEL TRAVEL RIGHT BOOM2 SWING PRIORITY DOZER EXTRA B PO PILOT OIL ENTRANCE Q2 Q1 V3 PLUG Q2 SUMM Q1 summation line for arm...

Page 42: ...ruction Equipment TRAVEL LEFT SWING OPTION ARM1 BOOM2 TRAVEL RIGHT BUCKET ARM2 BOOM1 TANK Pilot Press STRAIGHT TRAV V V OPT ARM CYL BOOM HOLDING VAVLE 1 15 9 12 3 4 6 8 16 11 7 13 14 17 2 10 R110 140...

Page 43: ...Page42 Construction Equipment R140W 7...

Page 44: ...Page43 Construction Equipment 1 SPOOLS OPTION Dozer for Wheel excavator BOOM1 ARM2 ARM REGENERATION BUCKET TRAVEL SWING BOOM2 ARM1 OPTION OPTION...

Page 45: ...Negative Relief v v PORT Relief v v Pn1 2 SPOOL Location 1 Pb1 Dozer up Pb20 Boom down Pb3 ARM In confluence Pc42 ARM Regeneration Pb4 ARM Regeneration cut Pb5 BUCKET Out Dr0 Drain Pc1 TRAVEL Reverse...

Page 46: ...Travel spool Ai Negative Relief v v Pn2 AUTO IDLE S W 3 SPOOL Location 2 PORT Relief v v Pd1 TRAVEL Reverse Pd2 SWING LH Pa21 BOOM RAISE confluence BOOM2 Pd40 ARM Out Pd5 OPTION B Pd6 OPTION C Pa1 DOZ...

Page 47: ...5 B4 Dr2 B2 B1 A1 A2 Dr1 Pb21 4 ATTACHMENT Supply port 1 Rs SWING Make up B5 BUCKET Out B4 OPTION A BREAKER B2 BOOM Down Dr2 Drain B1 OPTION DOZER Raise A5 BUCKET In A2 BOOM Raise A1 OPTION DOZER Down...

Page 48: ...5 C6 D1 C1 D5 C4 V3 C2 D4 D2 D6 Pc41 Dr3 5 ATTACHMENT SUPPLY port 2 C1 TRAVEL Reverse C2 SWING LH C4 ARM In C5 OPTION B C6 OPTION C D1 TRAVEL Forward D2 SWING RH D4 ARM Out D5 OPTION B D6 OPTION C Dr3...

Page 49: ...Page48 Construction Equipment Plug 6 NEGATIVE Control port Pn2 Pn1 2 8 P1 P2 Port P1 T1 P2 Plug...

Page 50: ...Page49 Construction Equipment OPTION C OPTION B ARM 1 BOOM2 SWING Priority SWING TRAVEL BUCKET ARM Regeneration ARM 2 BOOM 1 DOZER OPTION A Plug 7 CHECK Valves 1 Q2 Q1 Ks...

Page 51: ...KET ARM Regeneration ARM 2 BOOM 1 DOZER OPTION A LB1 LB2 L01 Qr ZM K1 K4 K3 CMR1 CMR2 Pu Plug Rs SWING Make up B5 BUCKET Out B4 OPTION A BREAKER B2 BOOM Down Dr2 Drain B1 OPTION DOZER Raise A5 BUCKET...

Page 52: ...ion Equipment OPTION C OPTION B ARM 1 BOOM2 SWING Priority SWING TRAVEL BUCKET ARM Regeneration ARM 2 BOOM 1 DOZER OPTION A 9 BUCKET Orifice When combined operation with BUCKET it allow to supply much...

Page 53: ...Page52 Construction Equipment 28 bar Drain 10 NEGATIVE Relief Valve Bypass passage RCV Neutral Bypass pressure up Pump flow decrease RCV Operation Bypass pressure down Pump flow increase...

Page 54: ...Page53 Construction Equipment Sest poppet Poppet Spring Check v v Piston A Piston B Spring B Pb21 DR3 Holding release port Drain 11 Holding valve 11 1 Composition...

Page 55: ...ase Holding release Pilot Port Pc41 Drain Port ARM In pilot port Pc40 Holding release Pilot port Pc41 Drain Port ARM Cyl ARM 1 SPOOL When ARM In operation PILOT pressure can act on Pc40 ARM 1 Spool Pc...

Page 56: ...Page55 Construction Equipment 11 3 ARM Holding Spring ARM CYL Check The Return oil from ARM CYL A is blocked by the Check valve C and so it can not flow to the ARM Spool section B...

Page 57: ...n Check v v While the ARM moves down from A to B position as the figure Return oil quantity will exceed the supply oil amount cause of the ARM gravity It can make a Cavitation To make stop Cavitation...

Page 58: ...ge57 Construction Equipment PILOT Supply port when ARM In operation Pc40 ARM 1 Spool Pc41 ARM Holding release Pc42 Selection v v Pb3 ARM 2 Spool Pc42 ARM 1 ARM 2 ARM Regen 12 2 ARM Regeneration circui...

Page 59: ...Page58 Construction Equipment Pc42 Pc42 12 3 ARM Regeneration Action ARM 1 ARM Regen ARM 2...

Page 60: ...Page59 Construction Equipment 13 AUTO IDLE One for Attachment the other one for travel operation check...

Page 61: ...0 330 330 330 330 330 330 330 VALVE POWER BOOST 360 360 360 360 360 360 360 360 360 360 PORT RELIEF 380 380 380 380 390 390 390 390 390 390 arm boom bucket 380 SWING MOTOR RELIEF PRESS 240 240 240 240...

Page 62: ...essure Measuring Point Pilot Main Test result Kg Remedy If not Boom 40Kg 330Kg Travel 40Kg 330Kg Deviation 40Kg 330Kg Arm 40Kg 330Kg 1 Condition S Mode max rpm 2 Test Items and Specifications 1 Proble...

Page 63: ...sure How to measure 1 disconnect Pilot Hose 2 connect the disconnect hose to Gauge T fitting 3 start the engine Pilot Pressure Attachment In Neutral Full Test result Kg Remarks If Not Boom See RCV Buc...

Page 64: ...easure 1 disconnect pilot hose 2 connect the disconnect hose to gauge T fitting 3 start the engine Relief Valve Pressure Kg Remarks Main 330 360Kg Adjust if need Boom 330 360Kg Bucket 330 360Kg Arm 33...

Page 65: ...heck of attachment 1 Problem All attachment speeds boom arm bucket are slow 2 Check Measure R H Travel L H Travel Swing Bucket out Bucket In Arm In Out Boom Up Swing L H Travel P1 330 150 250 170 330...

Page 66: ...he pressure for swing and L H relief to find if the pump 2 oil flows to pump1 As a result it was found that pump 2 oil flows to pump1 side of main control valve bucket confluence check valve broken 3...

Page 67: ...ment Pi2 Neg Control Regulator 1 P1 front M EPPR Valve 35 bar P2 rear Pilot Pump Pm2 Flow Cut Off Pm1 Flow Cut Off Pi1 Neg Control EPPR Pressure P1 P2 Pi Regulator 2 Connect to Engine 1 View of Pump a...

Page 68: ...quipment Section Y Y X X Y Y Section X X Regulator Parts Name Lever 1 Lever 2 Compensator Piston Pilot Piston Adjust Screw QMC Feed Back Lever Spool 2 The Type and circuit of regulator 2 The Type and...

Page 69: ...Page68 Construction Equipment 3 View of regulator 3 View of regulator The Portion of Horse Power Control The Portion of Flow Control...

Page 70: ...nput torque change amount Tightening amount of adjusting screw 953 Turn 1 4 1 4 1 4 1 4 1 4 L min 1 4 3 2 N m 32 7 35 1 34 7 34 7 39 1 3 2 3 4 3 4 4 4 50 5 4 4 Turn 1 4 1 4 1 4 1 4 1 4 1 4 Adjustment...

Page 71: ...12 3 0 17 0 17 0 15 0 15 0 15 0 13 Turn 1 4 1 4 1 4 1 4 1 4 1 4 min 1 2 000 2 000 2 100 2 100 1 900 1 900 Tightening amount of adjusting screw 627 Input torque change amount Turn N m 40 1 43 0 37 0 3...

Page 72: ...Page71 Construction Equipment Servo Piston Swash Plate Drive Shaft Support Cylinder Block Valve Plate Piston Shoe Gear Pump Ass y 5 Structure of pump 5 Structure of pump...

Page 73: ...Page72 Construction Equipment Servo Piston Swash Plate Drive Shaft Support Cylinder Block Valve Plate Piston Shoe 6 View main components of pump 6 View main components of pump...

Page 74: ...Page73 Construction Equipment...

Page 75: ...Page74 Construction Equipment 7 Symbol of Pump Assembly Actuator Cylinders Motors R210LC 7 R290LC 7A...

Page 76: ...Page75 Construction Equipment P1 P2 Pf EPPR Drain Drain R210LC 7...

Page 77: ...Page76 Construction Equipment R290LC 7 8 Pump Regulation Schematic...

Page 78: ...1 F2 B The pump power changes according to the selected mode on the cluster H S M U and work condition of the machine Therefore the CPU sets relevant currents towards the Electric Proportional Pressur...

Page 79: ...Page78 Construction Equipment Regulator consists of the negative flow control total horse power control and power shift control EPPR...

Page 80: ...Circuit Remark The Main Relief Valve MR limits the general working pressure to max 330 bar 360 bar for POWER BOOST This valve is situated on the MCV and has 2 adjust screws When the power boost button...

Page 81: ...6K 111L 202K 107L 177K 114L 161K 215L 92K 217L Emergency mode S mode H mode R210LC 7 standard Flow Rate l m in Delivery Pressure kgf cm2 118K 206L 2100rpm Emergency mode S mode H mode 175K 110L 177K 1...

Page 82: ...Page81 Construction Equipment 12 Pump Regulator Qmax control Qmin control Qmax Cut control Qmax control Qmin control Qmax Cut control...

Page 83: ...rew Adjustment Screw Tighten Flow Screw Loosen Flow Pilot P Q Min Flow Screw Adjustment Screw Loosen Flow Screw Tighten Flow Pilot P Q Pilot Flow Adjust Screw Screw Tighten Flow Screw Loosen Flow Grad...

Page 84: ...Screw First Horse Power Adjust Screw Screw Loosen Flow Screw Tighten Flow Second Horse Power Adjust Screw Screw Loosen Flow Screw Tighten Flow Pd Q 14 Control adjustment of regulator 14 Control adjus...

Page 85: ...Page84 Construction Equipment Minimum flow Maximum flow max REGULATOR REGULATOR...

Page 86: ...pressure reaches piston A Then the piston B goes back to the neutral position by the spring and the oil in the large chamber of the piston C is returned to the tank Now the oil is supplied to LH side...

Page 87: ...f stroke the pressure is increased Cylinder pressure spring pressure B D The pressure is applied at the piston D and compresses the spring D and B So the valve B moves to LH side and the oil enters th...

Page 88: ...the following steps 1 the pressure is created by restriction of the foot relief valve 2 the pressure apply to the piston A 3 the piston A is moved to LH side 4 the valve B is opened 5 the pressure flo...

Page 89: ...ne the pressure in the cylinder and in the position D is decreased Cylinder pressure spring force B D Then the oil in the cylinder C returns to the tank as shown in figure and the swash plate angle is...

Page 90: ...REAKER mode When selecting BREAKER mode on the cluster the CPU brings in the MAX FLOW solenoid which supplies pilot pressure towards both regulators Pm signal As a result the max flows will be cut off...

Page 91: ...MAX FLOW CUT OFF SIGNAL for P1 35 bar ON 0 bar OFF FRONT PUMP P2 35 bar MAX FLOW CUT OFF SIGNAL for P2 35 bar ON 0 bar OFF NEG CONTROL SIGNAL FOR P2 0 40bar On 7 models Max flow cut off Sig is ON afte...

Page 92: ...ith P1 P2 pressure on the power piston inside each regulator The power piston pilot piston are situated near each other and control the swash plate angle In case of significant drop of engine speed th...

Page 93: ...lected during operation the EPPR valve pressure is applied at the piston D The piston D compresses the spring and move the valve B to LH side Therefore the pump oil enters to the piston C and reduces...

Page 94: ...Page93 Construction Equipment...

Page 95: ...Page94 Construction Equipment R210LC 7 21 Flow Increasing Function...

Page 96: ...Page95 Construction Equipment R210LC 7 22 Flow Reducing Function...

Page 97: ...Page96 Construction Equipment R210LC 7 23 Overload Prevention Function...

Page 98: ...Page97 Construction Equipment R210LC 7 24 Flow Reset Function...

Page 99: ...ol 2 Total horsepower control 3 Adjustment of input horsepower 3 Adjustment of input horsepower Adjustment of outer spring Adjustment of inner spring 6 Adjustment of maximum and minimum flows 6 Adjust...

Page 100: ...Spec Remedy If not Unload 1750rpm Full 1700rpm Main Relief V V 330Kg In neutral 38Kg Pilot pressure 40Kg Adjust pilot relief V V EPPR Valve Unload 1850rpm Full 1800rpm Fr Fl pressure In full 5Kg Engi...

Page 101: ...Pump EPPR Unload Load Current mA Pressure Kg M 1950 1900 160 0 H 1850 1800 225 4 0 S 1750 1700 225 4 0 Auto Idle 1200 670 38 Mode 3 Specification for EPPR Valve 4 Measuring Method of EPPR Pressure By...

Page 102: ...6 1450 5 2 6 2 0 1560 1 8 1490 6 2 8 2 1 1600 2 0 1560 7 2 9 2 3 1650 2 1 1600 8 3 1 2 4 1700 2 3 1650 9 3 2 2 6 1750 2 4 1700 10 3 4 2 9 1850 2 6 1750 5 Specification of Accel and ECM signal By clus...

Page 103: ...Page102 Construction Equipment 6 Measuring Point for Main Pressure Attachment Pressure Remarks Main Relief 330 360 10 Boom Arm Bucket 330 360 10 Travel 360 10 Swing 265 10 Unit Kg Specification Table...

Page 104: ...ment 7 Fr Fl pressure How to measure 1 disconnect Fr or Fl hose 2 connect the disconnect hose to gauge T Fitting 3 start the engine Specification Table RCV Lever Test result Spec Remarks In Neutral Be...

Page 105: ...H Mode Max rpm 2 How to measure Rotate 1 turn and then measure time taken for next 3 revolution Test result Attachment RH LH Spec Second Remedy If not 1 speed 35 2 0 2 speed 20 2 0 3 Specifications Y...

Page 106: ...w to measure the Pressure Pull Travel lever fully Measure the travel pressure 2 Remedy according to the test result Travel Pressure Remedy Below 210Kg A adjuster should be adjusted Above 210Kg B adjus...

Page 107: ...igh Replace oil with one of proper viscosity 3 Check if suction strainer clogged Clean suction strainer 4 Air is intruding from pump suction line Retighten or replace parts 5 Check if reservoir breath...

Page 108: ...Page107 Construction Equipment R290LC 7A 4 3 Pilot Circuit...

Page 109: ...Page108 Construction Equipment R290LC 7A Operated Position...

Page 110: ...Page109 Construction Equipment 4 4 Swing Motor 1 View of Swing Motor R140LC 7...

Page 111: ...excavators have a similar swing device Reactionless valves Relief valves Time delay valve PG HOSE SH HOSE SWING MOTOR R210LC 7 ser nr below E1938 Remark Greasing of the output shaft of swing reduction...

Page 112: ...Page111 Construction Equipment R210LC 7 2 Swing Circuit Operation...

Page 113: ...Page112 Construction Equipment R290LC 7A...

Page 114: ...Page113 Construction Equipment R290LC 7A...

Page 115: ...Page114 Construction Equipment R290LC 7A Neutral Position Swing is not operated...

Page 116: ...Page115 Construction Equipment R290LC 7A 3 Swing Port Relief Valve...

Page 117: ...Page116 Construction Equipment R290LC 7A 110bar...

Page 118: ...me on the SH port of the swing motor this allows pilot oil 35 bar to enter in the brake section of the swing motor and lift up the swing piston resulting in releasing of the brake 4 Releasing of Swing...

Page 119: ...Page118 Construction Equipment R290LC 7A 5 Swing Brake Neutral Position...

Page 120: ...Page119 Construction Equipment R290LC 7A 6 Swing Brake Operating Position...

Page 121: ...Page120 Construction Equipment R290LC 7A...

Page 122: ...Page121 Construction Equipment R290LC 7A...

Page 123: ...Page122 Construction Equipment R290LC 7A 7 Antirotation Valve...

Page 124: ...Page123 Construction Equipment...

Page 125: ...When the spool of MCV is located at the neutral position the back pressure happens to Motor Outlet due to the force of inertia and it tries to rotate the motor reversely The pressure of Motor Outlet...

Page 126: ...Page125 Construction Equipment R290LC 7A 8 Make Up Valve...

Page 127: ...quipment Model Maker Relief Press R140LC 7 Jeil Sungbo R180LC 7 DongMyung Sungbo 240 R290LC 7A DongMyung Sungbo 265 R360LC 7A Jeil Sungbo 260 Jeil Sungbo DongMyung Sungbo Toshiba 240 R210LC 7 240 R500...

Page 128: ...relief valve faulty 4 Check if swing control valve spool move lightly by hand 5 Check swing brake release valve faulty 6 Check swing motor rotation and pilot valve Subject 2 Machine swings but does no...

Page 129: ...OAD RELIEF VALVE P2 GAUGE P1 GAUGE OVERLOAD RELIEF VALVE 4 PISTON 3 A DRAIN B 5 CHECK VALVE BALL 4 PARKING BRAKE RELEASE PRESS GAUGE P3 1 1 1 4 5 6 2 2 2 2 4 6 D1 P1 D2 P2 P3 A B Remark This travel mo...

Page 130: ...VE OVERLOAD RELIEF VALVE 2 SPEED CONTROL PORT Ps COUNTER BALANCE SPOOL P2 DRAIN T1 2 P1 SECOND SPEED SPOOL SECOND SPEED SPOOL P1 P2 P1 2 P1 2 2e SPEED NPTF 1 16 PLUGS Pm2 Pm1 Remark This travel motor...

Page 131: ...Page130 Construction Equipment 1 Relief Valve Role of the piston Reducing shock while the piston moves when relief pressure is activated to the valve Time delay effect Piston...

Page 132: ...Page131 Construction Equipment 2 Counterbalance Valve...

Page 133: ...Page132 Construction Equipment Speed Control Jeil 1st Speed Control...

Page 134: ...Page133 Construction Equipment Speed Control Jeil 2nd Speed Control...

Page 135: ...Page134 Construction Equipment Speed Control...

Page 136: ...Page135 Construction Equipment Speed Control P 290K A1 A2 Pi 40K Fp Fs P 290K Fa1 Fa2 Fa1 Fs Fa2 IF Pi 40kgf Main pressure 290kgf...

Page 137: ...ar Automatic shift press 270 bar Brake release press 9 bar Screw Orifice 1 Screw Orifice 2 Sec Relief valve 2 Counter Balance valve 1 R320LC 7 0456 Jeil Part nr Assy 31N9 40020 Check Valve 1st Speed A...

Page 138: ...Page137 Construction Equipment Regulating valve main pressure check point drain relief valve CHECK V V Pi Tilting rod 2nd speed spool...

Page 139: ...Page138 Construction Equipment...

Page 140: ...Page139 Construction Equipment 1 0 1 5...

Page 141: ...Page140 Construction Equipment C balance spool check V V...

Page 142: ...Page141 Construction Equipment Brake release A B C D brake release pressure 9Kg...

Page 143: ...Page142 Construction Equipment 2 Speed Spool 2 Speed Pi pressure 0 bar 1st speed Pi pressure 20 bar 2nd speed...

Page 144: ...Page143 Construction Equipment Main pressure 270 bar 1st speed changed 2 Speed Spool...

Page 145: ...Page144 Construction Equipment R290LC 7A Travel Motor Negative Brake...

Page 146: ...Page145 Construction Equipment R290LC 7A Brake Valve...

Page 147: ...Page146 Construction Equipment R290LC 7A Brake Valve Accelerating Position...

Page 148: ...pment Model Maker Relief Pressure bar R55 7 Jeil 220 DongMyung R180LC 7 DongMyung 330 R290LC 7A Jeil Sungbo 330 R360LC 7A DongMyung 360 Jeil Sungbo Jeil Sungbo Hydromatic R140LC 7 330 R210LC 7A 330 R5...

Page 149: ...re exchanged 3 Check if the symptom change when front and rear pump discharge hoses are exchanged hydraulic pump is broken 4 Check if metallic particles come out of drain port in travel reduction unit...

Page 150: ...9 Construction Equipment R290LC 7A 4 6 Remote Control Valve D1 D2 F 1 F 2 D1 D2 F1 F2 S1 F1 F2 S 1 For keeping the balance between the spring force and the force F1 F2 S1 F1 F2 Big spring S2 Small spr...

Page 151: ...Page150 Construction Equipment R290LC 7A 4 7 Remote Control Pedal...

Page 152: ...Page151 Construction Equipment R290LC 7A 4 8 Turning Joint...

Page 153: ...BREAKER OPEATION 1 Select BREAKER mode on the dash board So max flow cut off solenoid is activated and the flow is limited 2 Select correct Engine Speed via Accel Dial Switch for setting the right oil...

Page 154: ...110 143 185 2200 ENGINE R250LC 7 ENGINE R320LC 7 RPM RPM 1500 152 1450 183 1700 162 1550 196 1800 171 1650 208 1900 180 1750 221 2000 190 OIL FLOW l min NOT R110LC 7 CS26 Plug at cabin bottom is bridg...

Page 155: ...OUBLE ACTING CIRCUIT low flow FLOW SETTING SCREW P2 P1 Pn2 Neg Signal Pn1 Neg Signal Plug at cabin bottom is bridged in case of 2 way functioning system other case elec foot pedal mounting to be used...

Page 156: ...Page155 Construction Equipment 5 2 Single Acting Circuit...

Page 157: ...Page156 Construction Equipment 5 3 Double Acting Circuit...

Page 158: ...Page157 Construction Equipment 5 4 Comparison Table...

Page 159: ...00 R160LC 7 168 2 2100 143 2100 R170W 7 168 2 2100 143 2100 R180LC 7 168 2 2100 143 2100 R200W 7 220 2 1950 187 1950 R210NLC 7 220 2 1950 187 1950 R210LC 7 T2 220 2 1950 187 1950 R250LC 7 224 2 2000 1...

Page 160: ...Page159 Construction Equipment Electric New CAPO System Computer Aided Power Optimization...

Page 161: ...Page160 Construction Equipment 1 CAPO System 1 1 Power Mode Selection System Mechanically controlled CMS E G...

Page 162: ...Page161 Construction Equipment 1 1 Power Mode Selection System Electronically controlled CMS E G Tier 2 3 No Accel actuator DC Motor...

Page 163: ...Model Serial No Operating Hour Date ROBEX210LC 7 Hr Dec 2004 Location Spec Values Remarks SPEED SENSOR Resistance CD 17 1 2 0 2 0 4 0 25 Good SPEED SENSOR Voltage CD 17 1 2 2 28Vac 1 17 2 14Vac No go...

Page 164: ...ion between CPU Controller and CLUSTER is good 3 No ERROR CODE on CLUSTER 4 CONNECTOR CN 2 CN 9 CD 17 CN 51 on HARNESS check Finding rater in CN 2 connector 1 Re connection of CN 2 after removal of wa...

Page 165: ...n auto decel function on cluster is canceled HORN RIGHT HANDED POWER BOOST 360 bar for 8 sec OPTION this button is placed in serial line with switch on dash board and puts voltage on CN66 No auto dece...

Page 166: ...Page165 Construction Equipment 1 Monitor panel feature CLUSTER Connector 1 3 Monitor Panel Cluster...

Page 167: ...Page166 Construction Equipment 2 Cluster Check Procedure 1 Start key ON 2 Start of engine If not change cluster...

Page 168: ...Page167 Construction Equipment 3 How To Change The Program Version 1 X 2 X on The Cluster CHANGING PROGRAM VERSION VIA BUZZER STOP TRAVEL SPEED SWITCH EPPR V V CURRENT CHANGE...

Page 169: ...Page168 Construction Equipment R210LC 7 1001 R290LC 7 111 Ref RPM EPPR SETTING for H S Mode Refer to the SERVICE manual for the other model Option...

Page 170: ...Page169 Construction Equipment 4 Memory Set U mode Ex R360LC 7A Through U mode an operator can change the engine rpm and pump power and memorize it for his preference Latest production excavator...

Page 171: ...Page170 Construction Equipment 1 4 Communication RS485 SERIAL COMMUNICATION CAN J1939 COMMUNICATION RS232C SERIAL COMMUNICATION CPU CONTROLLER ECM CLUSTER Electronically controlled CMS E G Tier 2 3...

Page 172: ...Equipment 1 5 Automatic Deceleration System Operation Delay time 4 sec Work Travel neutral Accel dial position Higher than 4th E G speed down shift 1200 rpm Refer to the POWER Mode setting classified...

Page 173: ...Page172 Construction Equipment R210LC 7 Px Py 2 Circuit...

Page 174: ...ur Date ROBEX320LC 7 Hr Dec 2005 1 Accel dial location is in maximum position 2 Not drop to Auto deceleration speed in neutral position 3 Pressure switch check CD 6 Travel pressure SW check on CN 51 1...

Page 175: ...Page174 Construction Equipment Connection of CD 7 Work pressure SW on MCV 4 Remedy 5 Remarks Travel Work NC Normal Close type...

Page 176: ...Page175 Construction Equipment 7 Series 1 6 Power Boost System Power MODE condition H S or M Power Boost Pressure 330 360bar Location Main pump room Spec 24V 15 25...

Page 177: ...Page176 Construction Equipment 1 7 Travel Speed Control System Location Main pump room Spec 24V 15 25 Low speed Travel speed sol OFF Torque High High speed Travel speed sol ON Torque Low P...

Page 178: ...ine Overheat prevention 1 Automatic Warming Up Coolant Temperature Below 30 Accel Dial Lower than 3rd position E G speed 1000rpm 2 Overheat prevention Coolant Temperature Higher than 110 Accel Dial Hi...

Page 179: ...estarting CPU controller isolates the start motor control line after the engine is in operation condition Start relay disabled after 10sec of E G start By pass connector CN 92 can make the engine star...

Page 180: ...CT Malfunction of Anti restart Model Serial No Operating Hour Date ROBEX140LC 7 Oct 2004 1 Engine speed display and Battery charge lamp are normal 2 Check resistance between CN 50 11 and shsh 0 3 alwa...

Page 181: ...Page180 Construction Equipment 1 Separation of CN 92a and CN 92b 2 Confirmation of normal Anti restart function CN 50 11 4 Remedy 5 Remarks...

Page 182: ...Page181 Construction Equipment 1 Safety SOL 2 Power Booster SOL 330 360bar 3 Max Flow Cut Off SOL 85 100 4 Travel Speed 5 Boom Priority SOL 90 180 1 2 3 4 5 1 10 Location of Solenoid Valves...

Page 183: ...Page182 Construction Equipment 1 11 Work Power Mode Selection Refer to the next page for details...

Page 184: ...tion of the machine Work Mode Function Swing priority solenoid Max flow cut off solenoid Heavy Mode Operation speed for Boom arm is faster than G mode Off Off General Mode Default mode Swing operation...

Page 185: ...gnal Pb4 This signal commands a specific valve on the MCV At this time the arm operates with normal lower arm speed R210LC 7 R320LC 7 with Kawasaki MCV s PRIORITY SOLENOID HEAVY OFF GENERAL ON arm reg...

Page 186: ...Page185 Construction Equipment 1 12 Monitoring Display on Cluster...

Page 187: ...Page186 Construction Equipment 1 Description of Monitoring Display...

Page 188: ...Page187 Construction Equipment...

Page 189: ...Page188 Construction Equipment...

Page 190: ...Page189 Construction Equipment...

Page 191: ...ble After ignition on push 2 times the buzzer stop select switch simultaneously to get into the error code group OPTION OPTION OPTION OPTION OPTION OPTION OPTION OPTION OPTION OPTION OPTION OPTION Not...

Page 192: ...Page191 Construction Equipment 3 Engine Error Codes List for R290 360LC 7 Cummins QSB QSC...

Page 193: ...Page192 Construction Equipment...

Page 194: ...Page193 Construction Equipment...

Page 195: ...Page194 Construction Equipment 3 Engine Error Codes List for R450LC 7 Cummins QSM...

Page 196: ...Page195 Construction Equipment...

Page 197: ...Page196 Construction Equipment...

Page 198: ...Page197 Construction Equipment 4 Explanation of Error Code System Self Diagnostic System Memorised errors only visible at IGNITION ON not at running engine...

Page 199: ...ears it indicates serial communication problem between cluster and CPU Check Rx Tx Voltage on cluster Serial Rx line input Yellow 12V Serial Tx line output Blue 4V In case of no voltages check wiring...

Page 200: ...Page199 Construction Equipment CPU FAILURE COMMUNICATION FAILURE WIRING DIAGRAM 1 CPU Check Troubleshooting...

Page 201: ...ed on Normal R are Turned on Trouble on CPU or ROM Change the controller G and Y are Turned on Trouble on serial communication line Check serial lines between controller and cluster Three LED Are turn...

Page 202: ...resistor assures setting of fixed Eppr pressure which results in machine operation equal to S mode First models had emergency switch instead of connectors but principle is the same PRINCIPLE NORMAL 2...

Page 203: ...6 CN16A CN16 CN16B 3 3 ASSURING STARTING OF MACHINE Connect CN92 male female CN92 CN92 ALL EMERGENCY CONNECTORS NEAR CPU Emergency Resistor Emergency Connectors In case of faulty CPU starting is impos...

Page 204: ...Emergency Engine rpm Control 1 Disconnect the cable main cable 2 Connect the emergency cable 3 Disconnect the connector CN19 CN19A 4 Connect the other connector CN19 CN19B 5 Connect the connector CN 4...

Page 205: ...04 Construction Equipment 1 ENGINE THROTTLE LEVER INJECTION PUMP 5 ENGINE ACCEL ACTUATOR not for excavators with QS engines 2 EMERGENCY CABLE Push pull cable EMERGENCY CABLE Mechanically controlled CM...

Page 206: ...Page205 Construction Equipment 6 Preparation for Emergency Operation...

Page 207: ...Page206 Construction Equipment 1 14 Accel Actulator Type A General Type Reduction gear potentiometer box Mechanically controlled CMS E G...

Page 208: ...e207 Construction Equipment 1 15 Engine Speed Sensor not for excavators with QS engines A CUMMINS ENG B C series B MITSUBISHI ENG A CUMMINS ENG B C series B MITSUBISHI ENG Mechanically controlled CMS...

Page 209: ...Page208 Construction Equipment 1 16 Engine rpm control System Mechanically controlled CMS E G...

Page 210: ...Page209 Construction Equipment 1 17 Hydraulic Oil Flow Control system Mechanically controlled CMS E G...

Page 211: ...Page210 Construction Equipment 1 18 Input Output Signal 0 0 5 1 1 5 2 2 5 3 3 5 4 4 5 1 2 3 4 5 6 7 8 9 10 Accel P Meter EPPR RPM 1 Graphs for 4 signals Mechanically controlled CMS E G...

Page 212: ...9 1020 1020 35 2 2 2 1 4 1 4 1110 1110 31 3 2 3 1 6 1 6 1200 1200 31 4 2 5 1 8 1 9 1310 1360 9 5 2 6 2 1 2 2 1420 1470 9 6 2 8 2 3 2 4 1520 1560 9 7 3 0 2 5 2 6 1620 1670 9 8 3 1 2 8 2 9 1730 1780 9...

Page 213: ...ER MAX SOL O 24 4 HOUR METER O 24 Actual 16V 5 ENGINE PREHEATER O 24 6 CO CANCEL SOL O 24 7 BATTERY 24V PWR 24 CN 50 8 PUMP EPPR I 100 700 24 18 9 NC 10 RS232 Program dump I 0 5 PC Communication 11 AN...

Page 214: ...CEL ACT O I 0 24 Tier 1 Deactive Active condition 24 POWER IG PWR 24 Key ON 25 CAN_H COMM 0 5 Tier 2 With E G ECM CN 50 26 CAN_L COMM 0 5 Tier 2 With E G ECM 27 CAN_SHELD Tier 2 With E G ECM 28 GND Ma...

Page 215: ...1 only 5 NC 6 BOOM UP PS I 5 7 24V PRESS SENSOR PWR 24 8 GND PRESS SENSOR CN 51 9 ALTERNATOR LEVEL I 26 29 E G run condition 10 P1 PRESS SIG I 1 5 500 kg cm2 Option 11 P2 PRESS SIG I 1 5 12 P3 PRESS S...

Page 216: ...LEVEL SENSOR I 0 5 Active condition 25 TACHO SENSOR Tier 1 only CN 51 26 TACHO SENSOR I 1 28 pulse Tier 1 only 27 BRAKE FAIL SW 5 Wheel type only 28 T M OIL PS 5 Wheel type only 29 ACCEL SW 5 Wheel ty...

Page 217: ...gine Box with fuses CPU relays emergency resistor and or emergency switch connectors for Hyundai Cummins diagnosis software updating 13 R290LC 7 R140LC 7 R210LC 7 CN148 J1939 3 PIN Diagnosis for Cummi...

Page 218: ...Page217 Construction Equipment 2 1 Components Location Cabin Fuse box POWER RY SAFETY RY...

Page 219: ...uction Equipment 2 2 Fuses Relays LOCATION OUTSIDE OF CPU COMPARTMENT R210LC 7 Some machines R210LC 7 have circuit breakers which have to be reset in case of short circuit Safety Relay has an anti res...

Page 220: ...Page219 Construction Equipment 2 3 CONTINUAL POWER MASTER SW BATTERY RY FUSE BOX START KEY ROOM LAMP AC HEATER WIPER CPU B AC BLOWER CHECK Point 24V Circuit brakers or Fusible link...

Page 221: ...Page220 Construction Equipment 2 4 IG Circuit 1 Key SW ON 1 Battery RY ON 2 Start RY Power supplied 3 Power RY ON 4 IG Power supplied 2 CHECK Point 24V Operation Operation ON KEY SW BATT RY POWER RY...

Page 222: ...Page221 Construction Equipment 2 5 START Circuit KEY SW ST FUEL SUPPLY E G START FUEL CUT OFF Sol START MOTOR SAFETY RY CHECK Point 24V...

Page 223: ...Page222 Construction Equipment 2 6 CHARGING Circuit KEY SW E G Running condition ON ALTERNATOR BATT RY BATTERY CHARGING CHECK Point 25 29V...

Page 224: ...age223 Construction Equipment 2 7 LIGHTS Circuit Condition KEY SW ON CASETTRADIO CIGAR LIGHT AC HEATER HEAD LAMP ON SWITCH PANEL Back Light ON CHECK Point 24V Back light ON Back light ON Back light ON...

Page 225: ...Page224 Construction Equipment 2 8 MONITORING Circuit CPU CONTROLLER CLUSTER to PC SERIAL Communication between CPU Controller CLUSTER CHECK Point 0 11V Pulse FUSE Box POWER ON...

Page 226: ...uipment 2 9 WIPER WASHER Circuit FUSE Box POWER ON A INTERMITENT Operation B NORMAL Operation C WASHER Operation WIPER WASHER Operation WASHER ON CHECK Point GND 0 5V GND 0 5V GND 0 24V GND 0 5V GND 2...

Page 227: ...Page226 Construction Equipment...

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